Alcatel 1004A - 2004A, 2008A, 1012A, 2012A - IdealVac.com

27 Pages·2012·5.3 MB·English

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Technologie du vide
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High vacuum technology
Hochvakuumtechnik
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Notice technique
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Instruction manual
Technische Beschreibung
POMPES PRIMAl RES MECANIQUES
MECHANICAL FOREPUMPS
MECANISCHE FEINVAKUUMPUMPEN 'c,
TYPE/TYP: 1004A - 2004A - 2008A
1012A - 2012A - 2020A
ALCATEl
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MECHANICAL FOREPUMPS
TYPES 1004 A - 2004 A - 2008 A -1012 A - 2012 A - 2020 A
CONTENTS
Page Page
NOTES ..........••...•....•...•...•...•........•..... 19 4.2 Operating of Gas Ballast ........ . . . . . ... .. . . •. . . . .. 24
4.21 Starting ...... , . . . . . . . . . . . .. . . . . . . •. .. . . .. .. . . 24
4.22 Pumping Condensables . .. .. . . . .. . .... .. . . . . . 24
I. INTRODUCTION ................................ :.. 20 4.3 High-Pressure Pumping. . . . .. .. . . . . . .. . . .. . . . .. . . . . 24
4.4 Changing from One Type of 011 to Another. . . . . . . . 25
1.1 Description of Product. . . . . . . . . . .•. . .. .. . •.. . •. . ... 20
4.5 011 Level-Draining .. . . . .. .. .. .. . .. .. . . . .. . . .. . .. .. . 25
1.2 Electrical characteristics .. .. .. . .. .. .. .. .. ... . ... ... 20
4.6 Rushing .......................................... , 25
1.3 Dimensions.. .. .. . .. .. .. . .. . . . . . . . . . . .. .. ••. .. .. ... 20
1.4 Characteristics and Performance . . . . . . . . •. . . •. . . .. 20 V. DISASSEMBLY, CLEANING. AND REASSEMBLY. 26
5.1 disassembling Motor-Pump Assembly ............. 26
5.2 Disassembling Moving Parts....................... 26
II. OPERATING PRINCIPLE ... . . . .. ............... .... 21
5.21 Disassembly of Two-Stage Pumps . . . . . . . . . . . 26
'--'2. 1 Single-Stage Vane Pump. . . .. .. . .... .... . .. . . . .. ... 21 5.2.2 Disassembling of Single-Stage pumps. . . . . . . . 26
22 Two-Stage Vane Pump . . .. .. ............. . . . ...... 21 5.3 Cleaning Metal Parts . . . .. .. . . ... . . . . .... . .. . . . . .. . 27
um . ...........................................
21 5.4 ReplaCing Seals and Other Bastomer Parts. . . .. . . 27
24 Anti-Suckback System and Lubrication .... ........ 21 5:4.1 O·Rlngs ......... , . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
25 Gas Ballast . ....... . ............. .... . . . . . . ........ 21 5.4.2 Shaft Seals. . . .. . . .. . . . . . .. .. . . . .. . .. .. . ... .. . 27
5.4.3 Rat Gasket. . . . . . .• . . . • . . . .. .. . ••. . .. ... .. . . .. 27
5.5 Reassembly ............................... " ....... 27
III. MOUNTING AND INSTALlATION. . . . . . . . . . .. . . . . . .. 22 5.6 Tools..... .. . . . ........... .•...... ...•....••.. ..... 27
-3.1 Unpacking.................. .. .. . . . . . . . . . . •• . . . . . .. 22 VI. SPARE PARTS. . . . . . . • . . . . •. . . •. . . . ••. . .. .•. . . . . .. 28
3.2 Storage. . .. . . .. . . . . . . . . . . . . . . . . .. . . . . . . . . . •• . . . . . .. 22
6.1 Seal Kit.. . . . . . . . . . . . . . . . . . . . . . . •• . . . .•. . . . • . . . . . . .. 28
3.3 Choosing Correct 011 .. . . . . . .. .. . . .. .. .. . .... . . . ... 22
6.2 Maintenance Kit ........................ " .••. . .. .. 28
3.3.1 Why Correct 011 is Important. . . . . . . . .• . . . . . .. 22
6.3 Antl-suckback system kit .. .. .. ... .. ... .. . ... .. . ... 28
3.3.2 Recommended Oils .. .. .. .. .. .. .. .. . .. .. . . ... 22
3.3.3 Oxygen Pumping ....................•....... 23
VII. mOUBLESHOOTlNG............................. 29
3.4 Setup. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . •. . . . . . . . . . .. 23
3.4.1 Alling Pump with Oil..................... . . ... 23 VlII. ACCESSORIES.......... .. ............... ...... .. 30
3.4.2 Mechanical Connections ........•....•.. . . . .. 23
3.4.3 Accessory Table. .......... ...... .. .. ....... .. 23 a 1 Remote Controlled Gas Ballast .. . .. . •. . .. ... . .. ... 30
3.4.4 8ectrical Connection. . .. . . . . . . . . . .. . . •. .. . ... 23 6.2 011 Mist Eliminator .... , ......... ................... 31
8.3 Uquld Nitrogen trap NW 25... . . ............ ....... 32
8.4 Dust Filter NW 25. . .. ....... .. ......... ... ...... .... 33
IV. OPERATlON AND MAINTENANCE . . . . . . . . . •. . . . . .. 24
Dimensions............. . ...•...•...••....•............ 50
1.1 Starting............................................ 24 Divers Diagrams.. . . . .. .......... ..... ........... 51 to 56
'--" 4.1.1 Temperature .........•...•...•...••.......... 24 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .. 57 to 58
4.1.2 Starting ............ , .•. . . •. . . •. . . •. . . •• . . . . .. 24 Nomenclature and General Drawing.. . . . . .•. . ... 59 to 62
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II'
NOTES
APPUCATIONS AND UMITATIONS
'--- A1catal vane pumps are designed to ensure compl~te safety for the worker and the workplace when used properly.
It Is the user's responslbllty to follow the warnings, precautions. and maIntenance requirements set forth in thIs manual.
IMPORTANT NOTE:
Alcalel Siandard 1004 A - 2004 A - 2008 A - 1012 A • 2012 A - 2020 A, pU,mps are designed
to pump neutral or slightly corrosive gases.
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EQUIPMENT INSPECTION ON' DEUVERY
The equip me~t has been thoroughly tested, checked, and carefully packed before leaving the plant.
Shipper assumes responsibility for delivery. No claims relating to condition of materials shipped will be accepted unless submit·
ted wlthln eight days of receipt of goods.
No returned materials will be accepted without prior authorization of Alcatel.
Before unpacking equipment, please see § 3.1. ~ the equipment must be stored, see § 3.2.
We reserve the right to cancel the warranty:
- tf the equipment Is disassembled without authorization from Alcatel
- If spare parts not made'by ALCATEL are used
- If corrosive gases are pumped.
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1.3 DIMENSIONS
See Diagram 01 at the back of this book.
DESCRIPTION OF PRODUCT
~f~~§ft~~~~fl~~~,~::~~~~~:~arIend ustry. etc.}. 1.4 CHARACTERISTICS AND PERFORMANCE
medium vacuum (up to 1~ mbar)
II example to bacuks ead d Iinff uesvieorny paupmplplc oar-
U.,
serie have the following features In TECHNiCAl DATA 10041 2004 , 2008 , 1012 A 2012 A 2{l20 A
common : frequency "' "100 "101 , 01 01 .50. OJ 50 OJ
- direct transmission makes them highly compact and an Incorpora " 01
ted handle makes them portable; Number of stages 1 2 1 2 2
- they are equipped with an antinoise system ;
Nominal rotational
- an entlsuckback system ensures that the pump will retain its om 500 BOO 500 BOO 500 BOO 500 BOO BOO 500 "" I
vacuum tightness when stopped; ~." •• ,,' •
- a gas ballast allows condensable vapors to be pumped; m'1h '.5 .5,.' '.5 ,., 10 t5 18 5,7 18 to "
-stathned aIrndlse t aanndd eenxahbalues tn ucmonenroeucsti oancsc easreso aricecso rtdoi nbga toc oPnnneeuctreodp Free ail displacement Om •. , ,7 11 , 11 5,
(see § 3.4.2) ; • ,
- a sight glass on the 011 case Indicates the oil level ; ,ijr dj~alcement mt/h " '.5 7,' 11 13 " t5 18 1.
Pneuro method
- the principal parts are provided with pins to facilitate disassembly,
trheea ssspeemcbifliyc,a atinodn sr einp ltahcee mmeannut aol.f defective parts without affecting oPuartt iaGla ps rebsasUuerest v•.; tII- mb,a r <5.11)"1 < t.I~ < 1.10..1 ~ 2.lIrl <t"O" < 1.1~
Pumps In the Standard series are designed to pump neutral or nor .75 .B
mal atmosphere gases. The pump takes accessories to adapt It· to Oil capacity 1.12 1 1.18 0,'
other applications.
Weight •• (with
three·phase
WeIght •• (with kg 15.5 " t9 10.5 20 ..'8 7
~ ,,2 ELECTRICAL CHARACTERISTICS s/n~OPhaSB
mo. k, 22 24.5 25.5 25 28' 28.3
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The pumps can be supplied with different types of motors (voltage, Inlet and eKhausl
NW25
frequency, type of motor protection ...) . . PnlNrtlD f1anae
Depending of the destination, the motors can perform dlfferentiy, In
accordance with the user's country. .
The tables on diagram 05 "Electrical motors·, Indicate the caracte • Partial pressure measured by Pneurop method. .
ristlcs of different standard motors. The above specIfications are lor pumps filled with ALeAT EL 10 0 011. They may
""'-"'pon request, other types 01 motors can be delivered (special vol vary II other 011, are used (see § 3.3.2).
,ge. explosion proof. ..) . .. Change with motor type.
••• Option : NW 40.
20
II. OPERATING PRINCIPLE 2.3 OIL
011 has several Important functions in the pump:
- It lubricates mechanical components (bearings, shaft seals, rotor,
2.1 SINGLE-STAGE VANE PUMP vanes, etc.) ;
- It makes moving parts relatively tight by limiting Internal leakage;
- It carrles'away the heat produced by the compressed gases.
The functional part 01 a vane pump is composed of : ALCATEL has selected various types of oil for Its pump; they are lis
- a hollow cylindrical stator with an inlet and an QKhaust valves; ted In § 3.3.2.
- a rotor driven rotationally inside the stator (and off center with res-
pect to 11) to permit pumping :
- two vanes sliding In the rotor, forced against the stator bycenlrlfu
2.4 ANTI-SUCKBACK SYSTEM AND LUBRICATION
gal force and springs.
The pumping cycle Is as follows :
• Intake : As the vane passes In front of Inlet orifice an If the power supply should fail or the pump stops, an an'li-suckback
Increasing space Is formed into which the gas device prevents air or oil in the pump for being drawn back into the
from the chamber to be evacuated expands. chamber b.fillng evacuated: '
When the second vane passes, the space is - by flush-mounted O-rings between the surfaces of the functional
closed. elements (stators, flanges, frame. etc.) ;
• transfer: The gas trapped In the space between the two - by spring-loaded check valves placed In the exhaust orifices ;
vanes Is transferred to the exhaust orifice as the - by a system for automatically blocking the lubrication oil Injection
rotor rotates. channel, which also supplies oil to the pump. The operating prinCiple
• compre.slon : The space communicates with the exhaust, which is as follows (see diagram 2) :
Is fitted with a valve : the gas Is compressed until • when the pump Is rotating the all exerts a resistive torque on the all
apen the valve. Impeller cam wheel, preventing the cam from rotating. The eccentri
• •• hBUst : The gas Is expelled into the all casing when the city of the cam causes lever (I) to move and valve (3) to rise from Its'
pressure Is sufficient to open the valve. seat eQl, so that 011 flows in through the orifice (2).
• oil flowrate Is controlled by an oil jet (SO) mounted In the valve
. seat (36) (see general drawing).
'. wtien the pump is stopped, the olflmpetter cam recenters because
of its weight and the force of the spring: the lever returns, lelling the
valve drop back Into its seat, preventing all from entering.
2.15 GAS BALLAST
When condensable vapors are being pumped, in the ·compression"
phase gas Is compressed beyond Its saturated pressure and can
condense, Impairing pump penormance.
The gas ballast allows a quantity of air to be injected Into the second
u.n.I.,
stage of the pump during ·compresslon", to reduce the partial pres
sure of the pumped gas below Its saturated vapor pressure and thus
prevent condensation. In a single-stage pump the -aIr Is Injected Into
the main stage.
At the end of ·compresslon", the pressure In the discharge chamber
Is greater than atmospheric. An antl-suckback system (ball and
spring) prevents gas and all from being discharged Into the environ·
ment (see diagram below).
The saturated vapor pressure of a gas is higher when it is hot when It
is cold ; therefore, the pump must reach operating temperature
before pumping condensable vapors.
Using the gas ballast Increases the urtrmate pressure of the pump as
well as the temperature.
2.2 TW0-5TAGE VANE PUMP
TO Improve the backing pressure and displacement et low pressure,
two stages are connected In series. The second is similar to the first
both structurally and operationally. The gases drawn in by first stage
Ball
(lP low pressure), are transferred to second s'tage (HP high
&
pressure) and discharged through the high pressure discharge
valve.
COmp' ....l on
IIIOIUN11NG AND INSTALLATION 3.3.2 Recommended Oils
For the Standard pumps series Alcatel recommends oils listed in the
table below, Oils with similar characteristics can be used, however.
~~~~~~~~:.wlil
depend on : Influence on
ultimate
LIMITATIONS
: vacuum lines, etc. OIL APPLICATION vacuum of a ON USE
two-stage
pump'
any
ALCAlEL General purpose
100 paraffin-based
minerai 011 5.10-4 mbar Flammable
• good base pressure
• low backstreaming
'n~a"", eq~~ipn"~'tc8refully upon receipt. 00 not discard packing
prohcaese db eaes n checkedw iftho r damagean Idn shipmeAnlte. aI-f ALCATEL Antl'emulslon
f~~;~~ii;~~d;. required shipper advise 102 minerai 011
• drying 3.1o-~ mbar Flammable
~ no 011 when del1vered : all is shipped in separate • pumping waler vapor
• freeze-drying
ALCATEL Hydrocarbon·based
111 synlhetlc all wilh good
heat resistance 2.10'3 mbar Flammable
• pumping at high
3.2 STORAGE pressures
AlCATEL Highly stable
tt3 synthetic all Nonnammable
If the pump Is to be stored, reliability without special storage Perlluoropolyether
ptermecpaeurtaiotunrse Iso fg 5u atora 4n0te"Ced. for up to 3 months at an ambient • hcihgehmlyi cInaelsr t to 5.10'· mbar pFroerp sapreaclloianl
of pump
• pumping oxygen see § 4.4
After six mOnths, factors such as temperature, humidity, and salt air • plasma etching
can cause deterioration of cartain components: 0-rlng5 will harden, ALCATa Mineral aU vacuum
shaft seals will bond to shafts, and all will become contaminated. 200 distilled
A pump' may elCperlence op'erating difficulties under these condi- • pumping corrosive 5.10" mbar Flammable
t...-tlons. Before It is started It will have to be dlsassjl:mbled (see§ V) and products
il the seals replaced (5ee § 5.4). • reduced backstreamln
.lote1: We recommend keeping the pump filled with all If It will be
stored for longer than three months. ALCATEL Hydrocarbon'based
To do this, fill pump according to § 3.4.1 and run it for one hour atulli 300 mineral oil disti!led
mate vacuum so that all the parts will be lubricated (see § 4.1). Then under vacuum Flammable
stop the pump and store it after sealing inlet and exhaust ports • pumping corrosive
tightly (QuIck-connect clamp, centering ring, plug. ..) . products
5.10" mbar For special
• reduction of preparation
backstreamlng
Note 2 : Seal kits should also be stored carefully. Keep them away of pump
from heat and light (sunlight and ultraviolet) to prevent any harde • plasma etching see § 4.4
• high temperature
ning of the elastomers (see § 6.1) . opemtlon
Partlsl pressure measured by Pneurop method with a 2012 A AlCATEL
3.3 CHOOSING TltE OIL pump.
3.3.1 Why Correct Ollis Important
However. ALCATEL 100 011 can be replaced by the following fluids;
011 has numerous functions in the pump (see § 2.3). The correct oil Is
- ELF MOVIXA PV 100
critical for a good vacuum. The choice depends on :
- TURBELF SA 100
- chemical aggression and corrosion of the pumped products, - ELF BARELF F 100
- used accessories. - BP CS 100
- maintenance intervals that you want be compelled, -INLAND 15
- total operating cost.
-INLAND 19
DIHerent oils produce diNerent partial pressures in the same pump. - INVOIL 20
The partial pressure depends on Ihe salured vapor pressure of the
- SHELL VlTAEA 100
011. its viscosity, and Its ability to dissolve gases. Synthetic oils In par'
- TOTAL CORnS 100
tlcular produce a significant rise in the ultimate pressure of two - INVOIL 20 (Registered Trademark INLAND).
stage pumps.
In Ih·ls case: the characteristics can be different from those listed
on § 1.3 and In Ihe tahle above.
22
3.3.3 Oxygen pumping 3.4.3 Accessory Table
For certain appliCations, mixtures containing a certain concentration
of oxygen or even pure oxygen are used.
Mlnerat oils are flammabte i In addition they oxidize during pumpIng Description Port Location Function
and rapIdly tose their lubrlcallng properties. When the pumped N"~
gases contain mOf. than 30 % oxygen, minerai oils should not be 011 mist 068316 exhaust • separates 011 droplets and conta-
used. The following synthetic oils or oils classed In the same cate
eliminator mlnan! particles In exhausted
gory, should be used : gases Irom the machanlcal ya-
- ALCATEL 113 - FOMBUN YL VAC 25.6· - KRYTOX 15-25" -
cuum pumps.
DEMNUM S· 65·" - AFLUNOX 15.25. ...
Dust filter 068440 inlet • prevents dust particles larger than
6 microns from accumulating In
Oils auch aa trlaryl phosphate eater have already the pump and oil.
caused accidents; they should not b. used,
Liquid 786538 inlet • protects pump against con den-
nitrogen sable vapors.
Where use Is Intermlttent,ln case of Intennittent pumping, we can trap • rrreyents 011 from backstreaml"g
use mInerai based oils as ALCATEL 200 end ALCATEL 300. "to pumped chamber.
To prevent oxygen from accumulating In the equipment, the oil
casing must be litted with a neutral gas (dry nitrogen) purge to dilute Molecular 053379 Inlet • prevents oil backstreaming (when
the oxygen. The neutral gas now rate must be about five times the sieve used to back a diffusion pump
oxygen flowrate. Iiller or TMp).
Remote 068395 on frame • fecllltates pumping condensable
controlled vapors, regenerates pump oil, by
3.4 SETUP
gas ballast remote control.
Oil filter 068990 external • fillers 011 when pumping gases
3.4.1 Filling pump wtth 011 (DE) (220 V) device containin9 dangerous dUsts which
068991 could rapidly degrade oil quality.
Remove fill plug (16). FlII with oil to middle of sight glass (18). (115V)
This operation must be perfonned with pump stopped. Do not over'
tight the fill plug. Auxiliary 054257 between • when operating at ambient tem-
cooling fmmaond peratures above 40"C, a water
3.4.2 Mechanical Connections device motor cooling ring can be fitted.
a) Mounting on a Frame Shock 082691 between • allows pump to be mounted on
The pump can be mounted on a frame by using the 4 mounting mount (APEX base and a frame.
holes in base (3) and 4 special shock mounts (see § 3.4.3). lXA88 machine
NOTES: These mounts reduce the pump Vibrations bul will not Mod. D frame
hold the pump securely when the pumping assembly Is moved.
Clamp pump to frame before moving. Shock 052996 between • to be used when even the sligh-
b) Ventilation mount pump test vibrations must be eliminated
The pump and motor are equipped with a ventilation system. (special) frame (with TMP) (high-performance
When the pump Is Installed, the pump should be placed In a venU' 30d shock mount).
lated location. m:~~lne
Check ventilation holes on the pump and motor periodically 'or fra e
obstructions.
Alcatel pumps are designed to operate at an ambient tempera
ture of 10 to 40°C. If the temperature Is likely to rise above In general, use accessories whose tightn8$8 and materials are
40°C, an auxiliary COOling device can be used (see § 3.4.3). compatible wtth the pumped g8sell at both the Inlet and exhaust.
c) Inlet and Exhaust Ports At tha pump exhaust, the discharge circuit must be such that the
The pump Inlel and extlaust ports are equipped with 1$0 NW 40 resulting overpressure In the 011 case Is less than or equal toO,5 bar
nipples for Pneurop quick connectors to accept various stainless relative pressure,
steel, plastic, etc. tubing accessories (see diagram 7). See lable 'Selecting pumps and Accessories for Specific Applica
tions· at the back of this manual (diagram 6).
• Registered trademar1t of MONTEDISON 3.4.4 Electrical conn.ctlon
•• Regl~tered trademark 01 DU PONT DE NEMOURS
••• Registered trademark DAIKIN
•••• Registered trademark SCM Generally speaking, the molorshould be fused for1200/0of Its ratad
currenL
For series motors, see lable ·Protectlon of Electric Motors (see dia
gram 5).
a) Three-Phase Version
Hook up motor according to line voltage. The connecllons are
shown on the schematic located Inside the terminal box or on the
lid.
The pumps ore delivered with thelr motors connected to maxi
mum voltage. Switch on current briefly to check molar rotation
direction. The end of the shaft must rotate In the direction of the
arrow on the motor mounting plate.
b) Single-Phase Version
The motors are wired for the voltages shown In diagram 5. They
are supplied with a 6-foot power cord. The plug is equipped with a
ground pin which must be connected. The motor rotation direc
lion Is set at the factory.
OPERATION AND MAINTENANCE With ample lubrication, their performance with the gas baliast is
improved. On the other hand, the ultimate pressure which can be
achieved will be less than with a two-stage pump.
- Choice of 011 : use an 011 which is not miscible with the pumped
substances (see § 3.3.2).
- Pump'. exhaust assombly : avoid overpressure.
St"rt'ng: Be sure all bath temperature Is above 1Qoe before slar· Proceed as follows:
• remove valve (14),
where the pump will be used must be • do not use 011m ist eliminator (use a condenser instead at inlet),
• make sure there are no vertical lines allowing products to con
dense and return to the pumps oil casing.
opera-
• use a fume exhaust.
ling
- 'Startup ! Proceed as § 4.2.1.
Special case - Synthetic Oils - Durlng pumping : Monitor oil level. It may rise if all the pumped
See also § 4.4.b. condensates have not been vented.
These oils are much more viscous when cold than mInerai oils. In - After pumping ! Operate pump disconnected from system for
addition, to Improve pump lubrication when starting, add several ce's 1/2to one hour with gas ballast fully open. This regenerates the oil.
of oil through the intake. Then close gas ballast, stop pump, and drain condensates and oil·
For the same reason, avoid starting the pump at ambient temperatu condensate mixture (see § 4.5). As soon as clear oil appears at the
res below l8Ge. drain port, close it and top off with fresh oil (procedure can be facio
litated by fltling a drain cock to the drain port (connection G 318ft
4.1.2 Shirting ).
- Re.tartlng : II pump is still doesn't perform according to specifi·
- Check direetion of rolaUon of motor. cations, the ollis completely contaminated. Drain lIush (see § 4.6)
- It is normal for the all level to rise when hot (with in the limits of the then fill with fresh oil.
sight glass) because the all expands.
If problems occur, see § VII "Troubleshooting", 4.3 HIGH-PRESSURE PUMPING (P> 30 mbar)
4.2 OPERATION OF GAS BALLAST
With the pump Is operating at high pressure (P >30 mbar) perfor
mance depends on Ihe inlernal clearances In the pump: Ihe oil
4.2.1 Starting
which is partially penetrated by gases, serves only tor lubrication.
The principle of the gas baJiast Is described In § 2..5. When the pump As the pump heats up the oil becomes thinnet, and splashing and
1$ new or has not been operating for a long time, vapors or condensa misting losses Increase.
tes may have entered the pump by condensation. tntennlttenl Pumping
These substances mix with the oil and impair the pump characteris
If the pump operates only a short while at high pressure, top off with
tics. To regenerate oil, start pump at ultimate vacuum with inlet port lubricating 011 following the return to low pressure. Use an 011 mist eli
blocked: make sure It starts If the oil is especially cloudy or contami minator to prevent splashing and mlsl!ng losses (see § 8.2).
nated. Then, with the pump hot (after running for one hour), run
pump for about hall an hourto one hour (depending on the degree of Continuous Pumping
contamination) with gas ballast wide open. This procedure expells 11 the pump operates continuously at high pressure, all consumption
,.-LJlost condensabte products. Then close the gas ballastcontrof knob can become considerable. to the point where the level falls in the oil
~O) to restore the pump to ultimate vacuum. casing. lack of 011 may cause the pump to seize. In addition, the high
gas flow through the separator prevents the oil from returning to Ihe
~_2.2 Pumping Conden •• ble V.por. . casing.
When condensable substances are being pumped, the condensates The pump and Its 011 e!lminator must be modified for pumping under
will mix with the oil and impair the pump characteristlcs. these conditions. as shown in Iha following diagram.
To prevent this, do the following : The pump under these condllions the pump and oil mist eliminator
- Selecting Ihe pump. If the pump is to be used to pump large quan must ba modified as shown In the diagram below.
tities of condensables. use of a single-stage pump is recommen A device of this type draws the oil from the eliminator Ihrough the
ded. pump for lubricatlon.
The single stage pump allows the pumped gases to bypass the The components of a system of this kind will depend on the ultimate
functional assembly of the pump without condensing between two vacuum desired, the volume of gas pumped. and tha 011u sed. Other
staQ,§ s. arrangements arB possible; contact Alcate! for assistance.
HIGH PRESSURE PUMPING : Example of all recovery device (WARNING : The pump Is not airtight).
24
4.4 CHANGING FROM ONE TYPE OF OIL TO ANOTHER 4.5 OIL LEVEL - DRAINING
a) 011 Level
ALCATEL pumps are tested with ALCATEL 100 oil; a certain amount To use pump under optimum conditions, check oil level in oil sight
remains in the moving parts of the pump. glass periodically. Perform when pump Is not operating.
II you must use a different type of oil, proceed as follows : • Oil consumption may vary with conditions. Use of an all mist ellml·
nator can substantially reduce oil consumption by allowing oil to
a) When oils are compatible
flow back into the all casing.
This is the case when one mineral oil is replaced by another (for
• Periodic inspection enables the oil color to be compared with a
example ALCATEL 100 by ALCATEL 102).
sample of fresh all. It indicates the degree 01 contamination or
Simply flush pump (see § 4.6) using new oil, then fill (see § 3.4.1).
degradation.
II the oil is slightly cloudy (8 sign condensables are being absorbed) it
b) When oils are incompatible : synthetic oils or similar oils
can be regenerated with a gas ballast (cl, § 4.2).
This is the case when a mineral oil is replaced by a synthetic oil (for
If the oil Is brown, blackish, or smells "burnt" it has deteriorated. In
example ALCATEL 100 by ALCATEL 113).
this case, drain pump and rinse if necessary.
Synthetic oils are considered mutually Incompatible for practical
reasons, and they are expensive. Mixing them could cause cloudi· b) Draining Procedure
ness, which could be misinterpreted as a sign of contamination or
degradation. The pump must be drained when hot and after the oil case has been
For the same reasons, the clear oils of mineral (Alcatel 300) also vented to atmospheric pressure. First. isolate or disconnect the
expensive, will be considerate as synthetic oils. pump Irom the system. Then :
These remarks apply to these oils: ALCATEL 1" , ALCATEL 113, - tilt pump;
ALCATEl300. FOMBUN YL VAC 25-6*, INLAND TW, KRYTOX 15- - unscrew drain plug (16) on oil casing. When all the all has drained,
25", DEMNUM S 65"*, AFlUNOX 15.25. .... replace plug (16) temporarily and run pump for about 10 seconds
These oils are generally used in Chemical Series pumps. They can leaving inlet port open. This removes the oil from the pumping
also be used In standard pumps; proceed as follows: module;
- Completely disassemble and clean pump (see § V). - drain oil by removing plug (16) ;
- Change all seals (§ 5.4) and replace them by Viton seals. For this, - replace plug, then fill with fresh oil to the middle of all sight
order a seals kit for chemical pump, PIN 052624. glass (18).
- Reassemble but remove middle Jet (49) and Jet (SO) : replace the
latter by Jet PIN 052758. 4.6 FLUSHING
- Then fill with new 011 (see § 3.4.1).
Note: to replace a synthetic all by a minerai all, proceed as descri
bed in § 4.4.a). Draining can be followed by rinsing If the oil Is particularly dirty. This
operation requires a volume of oil equal to the capacity of the pump.
• Registered trademark 01 MONTEOISON. After draining oil casing (see § 4.5) replace plug (16). Run pump at
•• Registered trademark 01 DU PONT DE NEMOURS. atmospheric pressure allowing fresh oil to flow slowly into inlet port
••• Registered trademark 01 OAIKIN (100) after cleaning filter (29). Stop pump and drain flushing oil.
.... Registered trademark 01 SCM Replace plug and top off with fresh oil according 10 § 3.4.1 .
25
V. DISASSEMBLY, CLEANING 5.2.1 Disassembling Two-Stage Pumps 2004 A, 2008 A, and
2012 A, 2020 A.
AND REASSEMBLY
a) Removing HP Rotor (35)
- Remove rotor (35) by sliding it out off stator.
• Remove va.nes (47] "and lwings .(46).
MPOATANT I Befor. doIng any maintenance task, check the
pumping condition' of the Installation : toxicity, corrosion,
b) Removing HP Stator (40)
possible radIoactivity of pumped gas.s. Proc;:eed as follow.,
• Insert two screwdrivers into the two notches In stator (40) and
depending on the specific case :
proceed as In § "Removing rear Plate".
- flush system with dry nitrogen before doing any work on It i
- wear glov• •, goggl.s, and a mask If required; • Remove O·ring (55).
- ventilate area thoroughly and dlsas.emble equIpment
beneath a tume hood It necessary i c) Removing Central Plate (41)
- collect r• •l du .. In approprtate containers. • Insert two screwdrivers Into the two notches and proceed as tn
§ "RemovIng rear Plate". Remove O'ring (55).
• 011 jet (4.9) lubricates the first stage. Do not remove 1\ for clea'
ning. When reassembling, spray with compressed afr 10 remove
Routine maintenance of Alcalell004 A, 2004 A, 2008 A, 1012 A, any obstructions.
2012 A and 2020 A requires only periodic all changes.
In the ellenl of heavy contamination, wear, or an operating break
d) Removing LP Rotor (44)
down, the pump must be disassembled (see § VII).
Replace all seals whenever the pump is disassembled (see § 6.1), • Remove rotor (44).
The only tools needed are a few wrenches. found In any mainte • Remove vanes (48) and springs (46).
nance shop (see § 5.6).
Sefore disassembly, drain oil (see § 4.5). e) Removing LP stator (42)
The Ilrst step Is to remove the moving parts from the oil cassoT he • Insert two screwdrivers Into Ihe two notches and proceed as in
second step is to disassemble the moving parts. § "Removing rear Plate". Remove O-ring (55).
") f) Removing Front Plate (43)
• Insert two screwdrivers into the two notches and proceed as in
5.1 DISASSEMBUNG MOTOR-PUMP ASSEMBLY § -Removing rear Plate".
(see general drawing) • Remove spring (26) and gas ballast bearing (25).
• Remove O'rings (55) and (56).
- Stand pump on end with motor at top. resting on front of oil case.
IMPORTANT NOTE : 2004 A Pump
This greatly facUitates the first phase of disassembly.
When reas.embllng, do not confuse HP stator (40) and LP Bta
- Remove 4 nuts (H).
tor (42). HP stator (40) has an additional hole to admit air from
- Remove handle plate (4) together wilh motor. Be careful not to
gas ballast.
damage lIat gasket (12). The two parts of the motor coupling sepa·
,.......rate. one on the motor side and the other on the pump side.
~mps with an American standard motor have an adapter plate
(114) bfjt\v~~n handle plate (4) and motor.
- Set pump on base and remove oil case (2).
5.2 DISASSEMBLING MOVING PARTS
- Remove base (3) by unscrewing screw (A). - ~
• - Rotate fan (9) until set screw (F) can be unscrewed from bottom of ~
pump. ~ I .
Remove fan coupling (g) and spUne (19) . ,.., - ---;--.- '-
- Remove fell (11) and throw it.
- Unscrew screw (8) and remove retaining bracket (30).
Remove inlet plate (100). filter (29). and exhaust plate (103).
- Remove valve cover (60) by unscrewing screws (E).
STATOR lP 42 STATOR HP 40
Remove valve springs (61) and valves (57) (1004 A Pump: 1 valve).
- Disassembling Gas Ballast
• Remove screw (21). 5.2.2 Dlsas •• mbly of Singl.·Stage Pumps :
• Remove knob (20), piston (22). spring (24). and flap valve (23). 1004 A end 1012 A
- Dlsassemblln9 Sealing System a) Removing Rotor
Note :The sealing system Is set at the factory. It must be resetaNer
• Remove rotor (52) by sliding it out off stator.
disassembly (see reassembly, § 5.5 g). For sealing system malnte'
• Remove vanes (47) and springs (46).
nance, see § 6.3. However, rearplale cen be disassembled without
altering the setting 01 the sealing system.
• Remove Impeller cam (32) by remOving circlip (34), leaving anti· b) Removing Stator
suckback lever (54) In place. • Introduce two screwdrivers Into the two notches on stator (52)
Do not remove the 011 Jet (SO) for cleaning. When reassembling. and proceed as in § "Removing rear Plate".
spray with a jet of co",!pressed air to remove any obstructions. • Remove O-ring (55).
Since the clearances are particularly tight In the 1004 A and
1012 A pumps, rotors and stators are sold only all matched
- RemovIng Rear Plate (39)
pairs.
- • Unscrew three nuts (G).
• Insert two screwdrivers into the two notches. Twist simulta
neously screwdrivers to remove plate alignment pins. Remove c) Removing Front Plate (43)
flange straight retaining HP Rotor (35). Remove O"'fing (55). See § 5.2.1 f).
26